Cold formed product and method for making

ABSTRACT

Described is a method of making a cold formed product. The method includes the steps of forming a rod in diameter of annealed steel. At least a portion of the rod is positioned in a cavity and end portion of the rod is impacted to form a bulge in the rod in the cavity. The bulge is cold formed with a die to form an opening through the rod at the bulge surrounded by a upset portion. The opening and upset portion supporting a fastener positioned through the opening.

BACKGROUND AND SUMMARY

Described in the present application is a formed product and method for making the product. Specifically, the application is directed to a method of making a product by cold forming a rod into a desired shape.

Cold forming metal rods, particularly annealed steel, into parts and other products have had wide applicability in a variety of industries, including automotive and consumer products. These parts and products cold formed from metal rods may be bent, flattened, or formed into a variety of shapes, and are useful for making latches, levers, hooks, structural frames, and other components of numerous products. One problem with using metal rods for cold forming parts and products is the rods typically have a circular cross section, and the formed parts and products are typically attached to other components. A variety of means for attaching parts formed from metal rods have been proposed, including separate fasteners and hole(s) through the formed parts.

In the past, it was necessary to take the blank through a number of operations in multiple machines to form the part or product. For example, the metal rod was first partially flattened to form a portion with a flat surface, and then a drilled with another machine to form an opening through the flattened portion of rod for fastening the formed part. This approach is effective in making certain parts, but the diameter of the opening in the rod and the thickness of the upset formed from the rod surrounding the opening in the flattened section is limited. The diameter of the opening and surrounding upset section is limited both in the size of the rod and of the fastener that could be used without risking failure of the part. Moreover, this manufacturing sequence increases the cost as multiple machines in cold forming and drilling are needed to complete making of the part or product.

Accordingly, there has been a recognized need for a means and way of cold forming parts and products from metal rod with openings more simply and inexpensively, and with broader applications.

Presently disclosed is a method for making parts by cold forming comprising the steps of: forming a metal rod of a desired diameter and placing at least a portion of the rod in a cavity, impacting at least one of end portion of the rod to form a bulge in the rod in the cavity where an opening was desired in the finished product, cold forming the budge in the rod to form an opening through the rod at the bulge surrounded by a upset portion as part of the rod to support a fastener through the opening in the formed product.

Also disclose is method of a making a cold formed product comprising the steps of: forming a rod between 0.125 and 0.625 inch diameter of annealed steel, positioning in a cavity a portion of the rod where an opening is desired in the part or other product, impacting the rod at least one end portion to form a bulge in the rod in the cavity, and cold forming the rod at least at the budge with a die to form an opening through the rod at the bulge surrounded by a upset portion to support a fastener positioned through the opening in the formed product.

The method may also include the step of bending the rod into a desired cold formed product. The upset portion cold formed in the rod at the bulge may be generally between 0.25 and 1.25 inches in diameter or between 1.5 and 2.5 times the diameter of the rod used to form the part. The opening cold formed in the rod at the bulge may be generally between 0.05 and 0.375 in diameter.

Also disclosed is a method of making a cold formed product comprising the steps of: forming a rod between 0.125 and 0.625 inch in diameter of annealed steel, positioning at least two portions of the rod in two cavities, said two portions spaced from each end portion of the rod, and impacting at least one end portion of the rod to form bulges in the rod in each cavity; and cold forming at the bulges in the rod with at least one die an opening through the rod at each bulge surrounded by a upset portion to support a fastener for the formed product.

This method of making a cold formed product may also include the step of bending the cold formed rod into a desired product. The upset portion cold formed in the rod at the bulge may be generally between 0.25 and 1.25 inches in diameter or between 1.5 and 2.5 times the diameter of the rod used. The opening cold formed in the rod at the bulge may be generally between 0.05 and 0.375 in diameter.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A is a perspective view of a first embodiment of a finished cold formed product;

FIG. 1B is a perspective view of a second embodiment of a finished cold formed product;

FIG. 1C is a perspective view of a third embodiment of a finished cold formed product;

FIG. 1D is a perspective view of a fourth embodiment of a finished cold formed product;

FIG. 2A is a perspective view of a first step in forming the cold formed product;

FIG. 2B is a perspective view of a second step in forming the cold formed product;

FIG. 2C is a perspective view of a third step in forming the cold formed product;

FIG. 2D is a perspective view of a fourth step in forming the cold formed product;

FIG. 3A is a side view of the first step in forming the cold formed product;

FIG. 3B is a side view of the second step in forming the cold formed product;

FIG. 3C is a side view of the third step in forming the cold formed product;

FIG. 3D is a side view of the fourth step in forming the cold formed product;

FIG. 4A is a top view of the first step in forming the cold formed product;

FIG. 4B is a top view of the second step in forming the cold formed product;

FIG. 4C is a top view of the third step in forming the cold formed product;

FIG. 4D is a top view of the fourth step in forming the cold formed product;

FIG. 5A is a perspective view of the tooling used in the second step of forming the cold formed product;

FIG. 5B is a perspective view of the tooling used after the second step in forming the cold formed product;

FIG. 5C is a side view of the tooling used in the third step in forming the cold formed product;

FIG. 5D is a side view of the tooling after the third step in forming the cold formed product;

FIG. 5E is a side view of the tooling used in the fourth step in forming the cold formed product;

FIG. 5F is a side view of the tooling after the fourth step in forming the cold formed product; and

FIG. 5G is a perspective view of the formed cold formed product.

DETAILED DESCRIPTION

Described is a novel method of cold forming parts and other products. The disclosed method may be useful in making a variety cold formed products inexpensively. The following description may be modified within the scope of the following claims without departing from the scope of the claimed invention. Reference will be made to the attached figures, wherein numerals correspond to described components.

FIGS. 1A-D are perspective views of various cold formed products 100 manufactured using the disclosed cold forming method. The cold formed product 100 is a rod 102 that may include one or more bends 104 formed between end portions 106, 108. The cold formed product 100 includes at least one flattened portion 110 to provide a desired cold formed opening 112 surrounded by a upset 114. The opening 112 and surrounding upset 114 are sized to receive a fastener (not shown) for securing rod 102 cold formed into product 100 without risk of substantial failure. The cold formed product 100 may be formed, by way of example, to provide a hood latch for an automobile. Such a latch would be secured to the automobile body by fasteners, such as screws, bolts, rivets, or the like, through the opening 112. The flattened portion 110 of cold formed product 100 may be formed at one or more desired locations along the length of the rod 102, as shown in these figures.

In the first embodiment, illustrated in FIG. 1A, the flattened portion 110 is located away from the end portions 106, 108 of the cold formed product.

In the second embodiment, illustrated in FIG. 1B, the flattened portion 110 is located near one of the end portions 106, 108 of the cold formed product.

In the third embodiment, illustrated in FIG. 1C, the cold formed product 100 includes bends 104 positioned along the length of the rod 102 and flattened portions 110 are located near both end portions 106, 108.

In the fourth embodiment, illustrated in FIG. 1D, the cold formed product 100 includes flattened portions 110 at or near both end portions 106, 108 as well as at a flattened portion 110 in the mid-portion of the rod 102. Bends 104 are provided in the formed rod 102 between the separate flattened portions 110.

In the embodiments illustrated in FIGS. 1A-D, the formed rods 102 are shown having bends of up to 90°. These illustrated embodiments include flattened portions 110 either at opposite end portions or near the midpoint of the rod 102, or both. It is appreciated that the cold formed product 100 may have a variety of desired shapes, bend angles, and may be bent into various desired two or three-dimensional shapes. Further, flattened portions 110 may be positioned at any point along the length of the rod 102 as desired by functional or aesthetic design constraints.

The steps of manufacturing the cold formed product 100 are illustrated in FIGS. 2A-D, 3A-D, and 4A-D. FIGS. 2A-D show a perspective step-by-step view of the method; FIGS. 3A-D show a side step-by-step view of the method; and FIGS. 4A-D show a top step-by-step view of the method.

According to FIG. 2A, 3A, and 4A, a rod 120 is first formed of annealed steel. The rod includes first end portion 122 and second end portion 124 and has, as illustrated, a generally circular cross section having a diameter between 0.125 and 0.625 inch in diameter. It is contemplated that a rod having a different cross sectional shape may also be used, including oval, square, or rectangular cross-sectional shape with the same major dimension. The rod will varying in diameter to provide for the desired application of the cold formed product, and the particular size of the opening in the flattened portions and the desired size of the upset around that opening to avoid substantial risk of failure of the attachment formed with the upset and fastener.

It is further contemplated that the rod may be other than annealed steel. For example, the rod may be mild steel or other metal suitable for cold forming.

As shown in FIGS. 2B, 3B, and 4B, a bulge 126 is formed in the rod 120 by positioning a portion of the rod where an opening is desired to be formed in a cavity and impacting one or both ends portions 122, 124 of the rod. When the rod 120 is impacted, the portion of the rod 120 at the cavity expands in the cavity to form a bulge 126 in the rod 120. The bulge may be formed at or near one of the first end portion 122 or second end portion 124 or both. The bulge 126 has a desired diameter between 1.5 and 2.5 times the original diameter of the rod 120, and for example generally 2 times larger than the original diameter of the rod 120.

As illustrated, a single bulge 126 may been formed near one end portion 122 or 124 of the rod 120. The embodiment illustrated in FIG. 1 shows two separate bulges 126 formed near opposite end portions 122 and 124 of the rod 120, formed in separates cold forming steps or in one single cold forming step. In separate cold forming steps, a desired portion of the rod is positioned in a cavity and impacted on one or both end portions to form bulge 126 near the first end portion 122 of the rod. The rod is then removed from the first cavity and the second end portion is placed in the same or different cavity. The rod is once again impacted, causing a second bulge 126 to be formed in the rod at or near the second end portion 124. Alternatively, budges 126 near the first and second end portions 122 and 124 may be formed at the same time with multiple cavities in one cold forming step.

As shown in FIGS. 2C, 3C, and 4C, once the bulge 126 is formed in the rod 120, the bulge 126 is cold formed with a die to form opening 112 with surrounding upset 114 in the rod in flattened portion 128. The flattened portion 128 is substantially oval and has a thickness less than the diameter of the original rod 120. While the step of flattening the bulge may be formed in a separate step from forming the opening 112 and upset 114 in the bulge 126, the opening 112 through the rod and surrounding upset 114 may be formed in a single cold forming step with the flattened portion 128. In any case, the flattened portion 128 is a thickness less than the diameter of the rod.

As shown in FIGS. 2D, 3D, and 4D, after or concurrent with the previous cold forming step, an opening 112 is formed in generally center portion of the flattened portion 128 of the rod. The opening 112 may be formed by cold heading, stamping, or other type of suitable cold forming operation. The opening 112 generally extends through the flattened portion 128 forming upset 114 around the opening 112. The opening 112 is sized to receive a desired fastener, such as a screw, rivet, bolt or alignment pin. The upset 114 is sized to support the head of a fastener and secure the cold formed product 100 in place by a compression force without substantial risk of failure.

The opening 112 may be generally circular and has a diameter between 0.125 and 0.625 inch in diameter between. The upset 114 may have a diameter between 0.25 and 1.25 inches in diameter or between 1.5 and 2.5 times the diameter of the rod used to form the part. The opening cold formed in the rod at the bulge may be generally between 0.05 and 0.375 in diameter to provide for substantial fastening of the fastener to the cold formed product. As will be appreciated , the upset 114 has a diameter greater than the head diameter of a fastener sized to fit within the opening 112.

Finally, in an optional step, the cold formed product is bent into a desired shape. Possible shapes are illustrated in FIG. 1 where the cold formed product includes first and second right-angle bends, but other shapes and angles of bends are contemplated. The bends may be formed by a variety of means known to those having skill in the art.

The step of bending is typically a final step in the method, but the bending of the rod may be formed prior to any of the above described steps. For example, if it is desired to produce products having a variety of upset and opening diameters, it may be desired to bend the rod before to performing the step or steps of cold forming the opening 112 and upset 114.

FIGS. 5A-G show various steps in the manufacturing method of cold forming product. As shown in FIG. 5A, the rod may be inserted into a die having a cavity to form a bulge in the rod. The rod is impacted at one or both end portions, causing the rod to deform outwards into the shape of the cavity as shown in FIG. 5B. Once the bulge 126 has been formed in the rod, the rod may be removed from the cavity and a second portion of the rod positioned in the cavity to perform a second cold forming operation as shown in FIG. 5C.

In the second cold forming step, shown in FIGS. 5C-D, the rod at the bulge is flattened to reduce the thickness of the bulge to less than the diameter of the rod.

In either a concurrent or separate cold forming steps as illustrated in FIGS. 5E-F, an opening 112 and surrounding upset 114 is formed through the bulge for receiving a desired fastener. This opening may be cold formed using the same die as used the form the opening.

The finished cold formed product is shown in FIG. 5G. As shown in this illustration, the bulge is formed into a substantially flat portion and opening has been formed in the bulge with upset around the opening, in the same or separate cold forming steps. The opening is sized to receive a desired fastener, and the upset forms provides a support the head of the fastener, thereby securing the product to another component.

The above described process has been described as forming a product through various cold forming steps applied to a cold formed steel rod. As described, the method may be applied to cold form other materials, including aluminum, copper or stainless steel forming the metal rod.

The drawings and above description are intended to be exemplary rather than limiting, and those having skill in the art will recognize that various obvious alternatives of the above-described apparatus may be used without departing from the scope of the invention with the following claims. 

What is claimed is:
 1. A method of a making a cold formed product comprising the steps of: a. forming a rod between 0.125 and 0.625 inch in diameter of annealed steel, b. positioning at least a portion of the rod in a cavity and impacting end portions of the rod to form a bulge in the rod in the cavity, c. cold forming the budge in the rod with a die to form an opening through the rod at the bulge surrounded by a upset portion as part of the rod to support a fastener positioned by the rod through the opening.
 2. The method of a making a cold formed product as claimed in claim 1 comprising in addition the following step: d. bending the rod into a desired cold formed product.
 3. The method of a making a cold formed product as claimed in claim 1 the opening cold formed in rod at the bulge is between 0.05 and 0.375 inch in diameter.
 4. The method of a making a cold formed product as claimed in claim 1 the upset portion cold formed in the rod at the bulge is between 0.25 and 1.25 inches in diameter.
 5. The method of a making a cold formed product as claimed in claim 1 the upset portion cold formed in the rod at the bulge is between 1.5 and 2.5 times the diameter of the rod.
 6. A method of a making a cold formed product comprising the steps of: a. forming a rod between 0.125 and 0.625 inch in diameter of annealed steel, b. positioning at least two portion of the rod in a cavity or cavities spaced from each end portion of the rod and impacting end portions of the rod to form bulges in the rod in the cavity or cavities, c. cold forming the bulges in the rod with at least one die to form openings through the rod at each bulge each surrounded by a upset portion as part of the rod to support a fastener positioned through each opening in the rod.
 7. The method of a making a cold formed product as claimed in claim 5 comprising in addition the following step: d. bending the rod into a desired cold formed product.
 8. The method of a making a cold formed product as claimed in claim 5 the opening cold formed in the rod at the bulge is between 0.05 and 0.375 inch in diameter.
 9. The method of a making a cold formed product as claimed in claim 5 the upset portion cold formed in rod at the bulge is between 0.25 and 1.25 inches in diameter.
 10. The method of a making a cold formed product as claimed in claim 5 the upset portion cold formed in rod at the bulge is between 1.5 and 2.5 times the diameter of the rod.
 11. A method of a making a formed product comprising the steps of: a. forming a metal rod, b. positioning at least a portion of the rod in a cavity, c. impacting end portions of the rod to form a bulge in the rod in the cavity, d. flattening the budge in the rod and forming an opening through the rod surrounded by a upset portion at the bulge as part of the rod to position and support a fastener positioned by the rod through the opening.
 12. The method of a making a formed product as claimed in claim 9 comprising in addition the following step: e. bending the rod into a desired shape.
 13. The method of making a formed product as claimed in claim 9 where the rod includes first and second end portions and a bulge is formed near each of the first and second end portions;
 14. The method of making a formed product as claimed in claim 9 where the opening is less than the diameter of the rod.
 15. The method of making a formed product as claimed in claim 9 where the upset has a diameter at least approximately three times the diameter of the rod. 